Additive Manufacturing Irradiation Control for Heat Distribution
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Solution Overview
Problem
In additive manufacturing processes, inhomogeneous energy absorption by the object can lead to areas with uneven heat distribution, affecting the quality and stability of the manufacturing process.
Innovation Solution
A method and control device that define shape regions and select reference areas to generate correction factor modules for adjusting irradiation values, ensuring a homogeneous heat distribution and improved object quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If uniform irradiation is applied across all areas, then the manufacturing process is simple to control, but inhomogeneous heat distribution occurs leading to quality defects
Solution Approach 1:
The patent applies local quality by dividing the build area into multiple correction areas, each with its own correction factor module that specifies spatially resolved correction factors for irradiation values. This allows different regions to receive customized irradiation adjustments based on their specific heat absorption characteristics, thereby achieving uniform heat distribution across the entire build area while maintaining controllable complexity through systematic regionalization.
Solution Approach 2:
The patent implements parameter changes by dynamically adjusting irradiation parameters (intensity, duration, distribution) based on recorded heat data from reference areas. Correction factor modules modify irradiation values for correction areas by applying spatially resolved correction factors, transforming the irradiation process from uniform to non-uniform in a controlled manner to compensate for inhomogeneous heat absorption and achieve desired heat distribution uniformity.
2Manufacturing precision
If reference areas are monitored to adjust irradiation, then heat distribution uniformity improves, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the build area into reference areas (where heat data is recorded) and correction areas (where irradiation is adjusted). This segmentation allows the system to manage complexity by processing only specific reference areas for heat monitoring while applying corrections to other areas, rather than monitoring and controlling every point uniformly, thus achieving heat distribution uniformity with reduced overall system complexity.
Solution Approach 2:
The patent implements feedback by recording spatially resolved heat data from reference areas during solidification and using this information to generate correction factor modules for correction areas. This closed-loop feedback mechanism allows the system to automatically adjust irradiation parameters based on actual heat absorption measurements, achieving heat distribution uniformity while maintaining manageable process control complexity through automated adaptive correction.
3Manufacturing precision
If correction factor modules are generated for each area, then object quality improves, but computational complexity increases
Solution Approach 1:
The patent applies universality by creating correction factor modules that can be assigned to multiple correction areas with similar characteristics. Instead of generating completely independent correction modules for every single area, the system uses universal correction patterns that can be replicated and applied across multiple regions, thereby improving object quality through localized corrections while reducing computational complexity by avoiding redundant calculations for each individual area.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method optimizes energy input, minimizing mechanical stresses and achieving a uniform degree of porosity, thereby enhancing the quality and stability of additive manufacturing processes.
Implementation Method 1
selective laser melting... the build-up material is selectively solidified by spatially limited irradiation of the areas that will become part of the object after production... the powder grains of the build-up material are partially or completely melted using the energy locally introduced by the radiation at that point
Implementation Method 2
the energy applied by the energy beam is absorbed inhomogeneously by the object... the build-up material is selectively solidified by spatially limited irradiation... using the energy locally introduced by the radiation
Data Source
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AI summary
The invention relates to a method for controlling irradiation in a manufacturing process for the additive manufacturing of objects (2), wherein in a construction field (8) building material is solidified layer by layer in the form of object layers (O), corresponding to cross-sections of the objects (2) to be manufactured, by irradiating the building material, the method comprising the steps of: - defining a plurality of shape regions corresponding to one another in shape and/or size in the object layers (O) to be solidified, - selecting a number of reference regions (R) from the plurality of shape regions, wherein at least the remaining shape regions are defined as correction regions (K), - defining a number of target heat maps (S) which specify a desired heat distribution of correction regions (K) or a number of groups of correction regions (K),- Solidifying a number of selected reference areas (R) and recording spatially resolved thermal data (W) of the number of reference areas (R) during their solidification; - Generating a number of correction factor modules (F) for the correction areas (K) from the thermal data (W) and the target thermal maps (S), wherein each correction factor module (F) specifies spatially resolved correction factors for irradiation values or spatially resolved corrected irradiation values, and a correction factor module (F) is assigned to each correction area (K); - Solidifying at least the correction areas (K) based on the correction factor module (F) assigned to them. The invention further comprises a control device, a control unit, and a manufacturing device.